Note: Descriptions are shown in the official language in which they were submitted.
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CONNECTOR ASSEMBLY FOR END MOUNTING PANEL
MEMBERS
[0001] The present invention relates generally to electrical connector
assemblies
and, more particularly, to electrical connector assemblies for use with
electrical panel
members.
[0002] Connector assemblies are required to provide electrical power or
electrical
or electronic control signals between components, such as computers, printers,
auxiliary hardware, etc. Often, these components contain panel members, such
as
printed circuit boards, which are populated with miniaturized components to
provide
the desired electrical control. Typically, the connector assembly includes
electrical
contacts that extend from a housing that is secured adjacent to one end of the
panel
member. A mating connector assembly is configured for receiving the connector
assembly. The operational reliability of the component is directly affected by
the
integrity of the connection. That is, if there is an insufficient electrical
connection
between the contacts, the components cannot operate as intended.
[0003] In addition, the electrical connector assemblies between adjacent panel
members are configured to permit coupling by directing the electrical
connector
assemblies toward each other in only one direction.
[0004] The problem to be solved is an electrical connector assembly that is
secured to a panel member, which connector assembly being configured to couple
with a second connector assembly that is secured to a second panel member, the
connector assemblies capable of being brought into electrical contact with
each other
from a plurality of different directions.
[0005] The solution is provided by a connector assembly secured to a panel
member for electrically coupling with a second connector assembly secured to a
second panel member. Each of the connector assemblies includes a first contact
having a first portion and a second portion disposed at a first predetermined
spacing
from each other. A second contact is disposed a second predetermined spacing
from
the second portion, the first predetermined spacing of the first contact being
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configured and disposed to receive the second contact of the second connector
assembly. The second contacts and corresponding first contacts of the
connector
assembly and second connector assembly are capable of forming pivotable
connections.
[0006] An advantage of the present invention is that mating electrical
connector
assemblies form pivotable connections.
[0007] A further advantage of the present invention is that the mating
electrical
connector assemblies can be brought together from different directions.
[0008] A still further advantage of the present invention is that the panel
members of
mating electrical connector assemblies are capable of remaining at a fixed
orientation
with respect to each other.
[0009] A yet further advantage of the present invention is that the
orientation between
panel members permits changes in orientation with respect to each other.
[0010] A still yet further advantage of the present invention is that it
reduces the
number of component parts required to manufacture the connector assemblies.
[0011] A further advantage is that the connector assembly is hermaphroditic in
nature.
[0012] Other features and advantages of the present invention will be apparent
from the following more detailed description of the preferred embodiment,
taken in
conjunction with the accompanying drawings which illustrate, by way of
example, the
principles of the invention.
[0013] The invention will now be described by way of example with reference to
the accompanying drawings in which:
[0014] Figure 1 is a top perspective view of an embodiment of an electrical
contact construction of the present invention.
[0015] Figure 2 is a top perspective view of an embodiment of an electrical
contact construction of the present invention.
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[0016] Figure 3 is a top perspective view of a further embodiment of an
electrical
contact construction of the present invention.
[0017] Figure 4 is a top perspective view of an embodiment of a connector
assembly secured to a panel member of the present invention.
[0018] Figure 5 is a top perspective view of an embodiment of a connector
assembly secured to a panel member of the present invention.
[0019] Figure 6 is a top perspective view of mating electrical connector
assemblies prior to coupling secured to respective panel members of the
present
invention.
[0020] Figure 7 is a schematic elevation view of mating electrical connectors
of
the present invention, showing a plurality of directions in which the
connectors can be
brought together.
[0021] Figure 8 is an elevation view of coupled electrical connector
assemblies of
the present invention.
[0022] Figures 9-11 are cross sections of embodiments of mating connector
contact constructions of the present invention.
[0023] Figure 12 is an elevation view of an application showing a pair of
coupled
connectors of different panel members of the present invention.
[0024] Figure 13 is an elevation view similar to Figure 8, except each coupled
electrical connector assembly is rotated, i.e., pivotably connected, with
respect to the
other connector assembly of the present invention.
[0025] Figure 14 is a top perspective view of mating electrical connector
assemblies prior to coupling, with connector assemblies configured similar to
Figure
5, secured to respective panel members of the present invention.
[0026] Figure 15 is a schematic representation of one embodiment of mating
hermaphroditic connector assemblies of the present invention.
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[0027] Wherever possible, the same reference numbers will be used throughout
the drawings to refer to the same or like parts.
[0028] Referring to Figures 1-4, an electrical connector assembly 10 (Figure
4)
according to the present invention includes an arrangement of contacts 14, 15
that is
configured to couple with another arrangement of contacts 14', 15' (Figure 6).
In one
embodiment, as shown in Figure 1, contact 14 includes a base 16 extending from
one
end to a first portion 20 and from the other end to a second portion 22. First
portion
20 extends to an end 40 opposite base 16 and second portion 22 extends to an
end 42
opposite base 16. In one embodiment, base 16, first and second portions 20, 22
each
have an upper end 26 and a lower end 28, and first and second portions 20, 22
are
substantially parallel. It is to be understood that the terms upper and lower
are not
limiting, but merely provided to more easily identify features of the present
invention.
Contact 15 includes a base 17, said contact 15 extending from base 17 to an
end 43.
In one embodiment, contact 15, including base 17, includes an upper end 27 and
a
lower end 29.
[0029] As shown in Figure 1, a foot 18 extends outwardly and substantially
transverse to base 16 of contact 14 and has a surface 74 substantially
coincident with
or slightly lower than lower end 28. Similarly, a foot 19 extends outwardly
and
substantially transverse to base 17 of contact 15 and has a surface 75
substantially
coincident with or slightly lower than lower end 29. In another embodiment of
contact 14 (Figure 2); surface 74 of foot 18 extends past, or below, lower end
28, and
a foot 44 having a surface 76 extends transversely from lower end 28 of first
portion
20, in effect, raising contact 14 so that when contact 14 is placed upon a
substantially
flat surface, respective surfaces 74, 76 of feet 18, 44 are in contact with
the flat
surface. As further shown in Figure 2 with regard to contact 15, surface 75 of
foot 19
extends past, or below, lower end 29, and a foot 45 having a surface 77
extends
transversely from lower end 29, in effect, raising contact 15 so that when
contact 15 is
placed upon a substantially flat surface, respective surfaces 75, 77 of feet
19, 45 are in
contact with the flat surface.
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[0030] As shown in Figures 6 and 7, foot 18, 18', 19, 19' and foot 44, 45 (not
shown) can be used to securely mount respective contacts 14, 14', 15, 15' to a
corresponding panel member 12. In one mounting technique (not shown), a solder
containing paste is masked onto the surface of panel member 12 so that foot
18, 44
and/or foot 19, 45 is disposed on the paste. Panel member 12 is then subjected
to
sufficient heat to flow the paste, establishing a bonded joint between panel
member 12
and each foot 18, 19, 44, 45 (Figure 2) or between panel member 12 and foot
18, 19
(Figure 1). However, other suitable conductive fastening techniques, including
mechanical fasteners, adhesives or other thermal processes can be used to
secure foot
18, 19 or feet 18, 19, 44, 45 to panel member 12.
[0031] In one embodiment, an interfering retainer 36 (Figure 1) is formed in
each
of first portion 20 and second portion 22 to secure contact 14 to a housing 50
(Figure
4). In addition, a retainer 37 (Figure 1) is formed in contact 15 to secure
contact 15 to
a housing 50 (Figure 4). Further, Figure 1 shows an angled region 24 formed
adjacent
to upper end 26 and end 40 of first portion 20, and an angled region 46 formed
adjacent to lower end 28 and end 40 of first portion 20. Also, as shown in
Figure 1,
angled region 25 is formed adjacent to upper end 26 and end 42 of second
portion 22,
and an angled region 47 is formed adjacent to lower end 28 and end 42 of
second
portion 22. As further shown in Figure 1, a taper 30 is formed in contact 15
adjacent
to upper end 27 and end 43, and a taper 32 is formed in contact 15 adjacent to
lower
end 29 and end 43. As shown in Figures 1-4, an optional protrusion 38 extends
outwardly from second portion 22 toward first portion 20 to provide an
improved
electrical connection with a mating connector. It is to be understood that
protrusion
38 could also extend outwardly from first portion 20 toward second portion 22,
or
protrusion 38 could be formed in each of first and second portions 20, 22. In
addition,
an optional protrusion 39 extends outwardly from contact 15 (Figure 1). For
reasons
discussed in further detail below, an arrangement of contacts 14, 15 forms a
pivotable
connection with a corresponding arrangement of contacts 14', 15' (Figure 6).
[0032] Referring to Figure 3, which is another embodiment of contact 14 that
is
otherwise similar to the contact 14 embodiment of Figure 2, an angled portion
48 is
formed adjacent to end 40 of first portion 20. In addition, an angled portion
49 is
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formed adjacent to end 42 of second portion 22. Angled portions 48, 49 provide
a
lead-in transition to facilitate end mating, such as by direction 60, as shown
in Figure
7. It is to be understood that angled portions 24, 46, 25, 47, 48, 49 can
extend along a
portion of the periphery adjacent respective ends 40, 42 of first and second
portions
20, 22, or extend substantially contiguously along the periphery adjacent
respective
ends 40, 42 of first and second portions 20, 22.
[0033] Referring to Figure 6, contacts 14, 15 are composed of a metal such as
brass or phosphor bronze, or other sufficiently electrically conductive
material so that
electrical energy is conducted from feet 18, 44, 45 (44, 45 not shown in
figure 6)
through first and second portions 20, 22 of contact 14 and contact 15 to an
arrangement of mating contacts 14', 15' in a manner that does not
substantially
adversely affect the performance of components mounted to each panel member
12.
[0034] Referring to Figure 4, a housing 50 includes an opening 54 configured
to
receive contact 14 and an opening 56 configured to receive contact 15. To
mechanically secure housing 50 to panel member 12, a foot 52, or a plurality
of feet
52, that is secured to housing 50 is brought into contact with panel member
12, foot
52 being secured to panel member 12. Foot 52 can be secured to panel member 12
in
a manner similar to the technique used to secure feet 18, 44 to panel member
12 as
previously discussed. In one embodiment of housing 50, contact 14 is secured
to
housing 50 by virtue of retainers 36 (Figure 1) that engage opposing walls of
opening
54, and contact 15 is secured to housing 50 by virtue of retainer 37 (Figure
1) that
engages one wall of opening 56. As shown in Figure 4, housing 50 is configured
so
that first and second portions 20, 22 and contact 15 are disposed
substantially
perpendicular to panel member 12. Also as shown in Figure 4, angled regions
24, 46,
25, 47 and tapers 30, 32 extend outwardly from housing 50 through openings 54,
56.
In an 'alternate embodiment, front surface portions 70, 72, 74 of housing 50
can
extend outwardly toward ends 40, 42 of first and second portions 20, 22 and
end 43 of
contact 15 to vertically separate and enclose first and second portions 20, 22
and
contact 15. Housing 50 can be composed of any material having sufficient
electrical
insulating properties and strength and stiffness properties suitable for use
with
connector assembly 10, such as nylon or polyester thermoplastics.
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[0035] Referring to Figure 5, housing 50 is similar to the embodiment of
Figure 4,
except that housing 50 in Figure 5 is configured to secure contacts 14 so that
first and
second portions 20, 22 of contact 14 and contact 15 are arranged horizontally
along
the surface of panel member 12, i.e., substantially parallel to panel member
12, with
contacts 14, 15 disposed substantially perpendicular, i.e., stacked
vertically, to the
panel member 12. In other words, as shown in Figure 5, housing 50 is
configured to
secure contacts 14, 15 so that first and second portions 20, 22 of contact 14
and
contact 15 are arranged vertically along a portion of panel member 12 with
first and
second portions of contact 14 and contact 15 disposed substantially parallel
to panel
member 12. Upon connecting contacts 14, 15 of the connector assemblies 10 of
each
of Figures 4 and 5, panel members 12 would be perpendicular to each other.
Alternately, connecting two panel members 12 as shown in Figure 14 with mating
connector assemblies similar in nature to that shown in Figure 5, permits
panel
members 12 to rotate substantially in the plane of the panel members 12, the
extent of
rotation being limited by the mating panel member 12.
[0036] Figure 6 shows mating connector assemblies 10, 10' aligned for
coupling,
each connector assembly 10, 10' secured to a respective panel member 12. Upon
directing each connector assembly 10' into engagement with its respective
connector
assembly 10, contact 15' is received between corresponding first and second
portions
20, 22 of contact 14. Likewise, contact 15 of connector assembly 10 is
received
between corresponding first and second portions 20', 22' of contact 14' of
connector
assembly 10'. Due to the construction of contacts 14, 15 of connector assembly
10
and contacts 14', 15' of connector assembly 10', as shown by Figure 7,
connector
assemblies 10, 10' can be brought together from a plurality of directions. For
example, contacts 14', 15' of connector assembly 10' can be brought into
mating
contact or coupled with contacts 14, 15 of connector assembly 10 along
direction 58,
for example. That is, from a position vertically above contacts 14, 15,
contacts 14',
15' can be lowered along direction 58 so that lower end 28' of contact 14' and
lower
end 29' of contact 15' engage upper end 26 of contact 14 and upper end 27 of
contact
15 until full engagement or coupling is achieved. It is to be understood that,
in one
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embodiment, connector assemblies 10, 10' are substantially the same and mate
due to
their hermaphroditic nature.
[0037] Alternately, contacts 14, 15 of connector assembly 10 and contacts 14',
15'
of connector assembly 10' can be coupled or brought together to achieve mating
contacts 68 (Figure 7) along direction 60, for example. In other words, where
contacts 14, 14', 15, 15' are aligned, contacts 14', 15' can be moved along
direction 60
so that ends 40, 42, 43 begin to engage ends 40', 42', 43' until full
engagement is
achieved. Engagement along direction 60 can be made easier when one set of
contact
14 (or 14') includes angled portion 48 (or 48') andlor angled portion 49 (or
49')
(Figure 3). In addition, contacts 14, 15 of connector assembly 10 and contacts
14', 15'
of connector assembly 10' can be brought into mating contact or coupled with
connector assembly 10 along direction 62, for example. That is, from a
position
vertically below contacts 14, 15 of connector assembly 10, contacts 14', 15'
of
connector assembly 10' can be raised along direction 62 so that upper end 26'
of
contact 14' and upper end 27' of contact 15' engage lower ends 28 of contact
14 and
lower end 29 of contact 15 until full engagement or coupling is achieved.
[0038] It is to be further noted that while connector assemblies 10, 10' can
be
brought together from a plurality of directions, by virtue of the pivotable or
hinge-like
connections, the panel assemblies 10, 10' can either be maintained parallel to
each
other, or continuously rotated with respect to each other, such as, maintained
non-
parallel to each other during assembly. That is, the term pivotable connection
as used
herein is defined to mean that in the case of mating contacts 14 and 14', each
contact
can be rotated with respect to each other, such as comparing Figures 8 and 13.
In
other words, as shown in Figure 8, contacts 14 and 14' are mated so that
corresponding panel members 12 are disposed substantially parallel to each
other. As
shown in Figure 13, contacts 14 and 14' are rotated with respect to each other
so that
the corresponding panel members 12 are disposed at an angle to each other.
However, while a pivotable connection as shown between Figures 8 and 13 are
hinge-
like, the pivotable connection is not constrained to rotate about a specific
axis. Stated
another way, unlike a hinge, the pivotable connection of the present invention
lacks a
hinge pin, thus permitting an amount of translational sliding movement between
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contacts 14 and 14'. In addition, as previously discussed with respect to
mating the
connector assemblies 10 of Figures 4, 5, alteration of housing 50
constructions can
provide any orientation, i.e., any angular measurement, between panel members
12,
which orientation being changeable, as desired.
[0039] In addition to providing pivotable connections between coupled
connector
assemblies 10, 10', the connections achieved also provide an enhanced
electrical
connection therebetween. For example, Figure 8 shows a pair of coupled
electrical
connector assemblies having mating contacts 68, also referred to as contacts
14, 14',
15, 15'. Figures 9-10 are cross sections each taken along line 9-9 of Figure 8
for the
pair of mating contacts 68 or contacts 14, 14', 15, 15'. For convenience,
contacts 14,
14', 15, 15' are shown as identical components, with the only difference
between
corresponding portions being the superscripted apostrophe " ' " following the
numerical designation. Thus, in Figure 9, contact 15 is secured between first
portion
20' and second portion 22' of contact 14', and likewise, contact 15' is
secured between
first portion 20 and second portion 22 of contact 14. To enhance the
electrical
connection between mating contacts 68, protrusions 38, 38', 39, 39' can be
employed,
such as shown in Figures 1-3 for protrusions 38, 39. As shown in Figure 9,
protrusion
39' increases the effective thickness of contact 15', and is sized so that the
effective
thickness of contact 15' is greater than the distance between first and second
portions
20, 22 of contact 14. Thus, upon the insertion of contact 15', including
protrusion 39',
between first and second portions 20, 22, first and second portions 20, 22 are
urged
further apart, producing a compressive contact force on opposite sides of
contact 15'
(including protrusion 39'). This compressive force provides improved
electrical
contact between the abutting portions of contact 15', including protrusion
39', and
corresponding first and second portions 20, 22.
[0040] Similarly, as further shown in Figure 9, protrusion 39 increases the
effective thickness of contact 15, and is sized so that the effective
thickness of contact
15 is greater than the distance between first and second portions 20', 22' of
contact 14'.
Thus, upon the insertion of contact 15, including protrusion 39, between first
and
second portions 20', 22', first and second portions 20', 22' are urged further
apart,
producing a compressive contact force on opposite sides of contact 15
(including
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protrusion 39). This compressive force provides improved electrical contact
between
the abutting portions of contact 15, including protrusion 39, and
corresponding first
and second portions 20', 22'. As shown in Figure 9, protrusions 38, 39' and
38, 39
abut each other. While protrusions 38, 38', 39, 39' have been generally
depicted in the
figures as having a spherical or circular profile, it is to be understood that
the
protrusions can have any number of suitable shapes, including flattened apexes
to
increase the amount of surface area between the protrusion 38, 38', 39, 39'
and the
adjacent first or second portions 20, 20', 22, 22' of contact 14, 14' and
contact 15, 15'.
[0041] In another embodiment of mating contacts 68, Figure 10 is similar to
Figure 9, with the inclusion of protrusions 64, 64' formed in respective first
portions
20, 20'. As shown, protrusions 64, 64' extend outwardly from respective first
portions
20, 20' in the same direction as respective protrusions 39, 39' formed in
adjacent
contact 15, 15' when contacts 14, 14', 15, 15' are coupled. In one embodiment,
protrusions 64, 64' are smaller than protrusions 39, 39'. However, protrusions
64, 64'
are sized and disposed so that protrusions 64, 64' and corresponding
protrusions 39,
39' are aligned when mating contacts 68 are achieved upon assembly of
connector
assemblies 10, 10'. Once connector assemblies 10, 10' are assembled, upon
sufficient
movement of contact 14 with respect to contact 15' or of contact 14' with
respect to
contact 15, protrusions 64, 64' abut indented portion 70, 70' opposite
protrusions 39,
39' to resist further movement in the direction of the abutting contact.
Stated another
way, protrusions 64, 64' act to help maintain abutting protrusions 39, 39' and
38, 38' in
abutting contact with each other, providing an enhanced physical and
electrical
contact between mating contacts 68.
[0042] In another embodiment of mating contacts 68, Figure 11 is similar to
Figure 9, with the exclusion of protrusions 38, 38', 39, 39'. That is, as
shown,
protrusions 38, 38', 39, 39' are substantially absent.
[0043] Referring to Figure 12, an application of connector assemblies 10 with
panel members 12 is discussed. As shown, panel members 12 contain light
emitting
diodes 66 for providing illumination to a structural space (not shown). Panel
members 12 are secured in position, such as by an adhesive strip, so that once
affixed
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to a surface of the structural space, removal and interconnection is extremely
difficult,
if not impossible to achieve. Since the panel members 12 may be of extended
length
either singly or in total, it is not practical for an installer to pre-
assemble all of the
panel members 12 together prior to installation. Additionally, once a first
panel
member 12 is affixed to the structural space surface, it is not possible to
slidably
couple a second panel member 12 to the first panel member 12 using
conventional
"straight-on" end-to-end connections. That is, contacts 14, 15 must be
configured to
permit coupling from different directions, such as direction 58 (Figure 7),
which is
permitting by the present invention.
[0044] It is to be understood that although one set of contacts 14, 15 and
contacts
14', 15' are respectively shown for hermaphroditic connector assemblies 10,
10' in
Figure 6, any multiple of contacts 14, 15 and contacts 14', 15' can be
arranged on
other embodiments of connector assemblies 10, 10', so long as the same number
of
contacts 14, 14' and contacts 15, 15' are arranged symmetrically on each side
of the
centerline 78 of the connector assembly 10, 10'. For ease of illustration,
referring to
Figure 15, contacts 14, 14' are represented as F, F', since contacts 14, 14'
are female
contacts, and contacts 15, 15' are represented as M, M', since contacts 15,
15' are male
contacts. Stated another way, as shown in Figure 15, there is one F contact
immediately adjacent to centerline 78 on one side of centerline 78 of the
connector
assembly 10, so there must be one M contact immediately adjacent to centerline
78 on
the opposite side of centerline 78 of the connector assembly 10. Similarly,
the two M
contacts disposed along the outer positions on one side of centerline 78 of
connector
assembly 10 corresponds to the two F contacts disposed along the outer
positions on
the other side of centerline 78 of connector assembly 10.
[0045] It is to be understood that while the connector assemblies shown
contain
one pair of connector contacts secured in a housing, that one connector
contact or
more than two connector contacts can be contained in a housing to form a
connector
assembly. Further, a plurality of connector assemblies can be used to
interconnect
adjacent panel members.
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[0046] While the invention has been described with reference to a preferred
embodiment, it will be understood by those skilled in the art that various
changes may
be made and equivalents may be substituted for elements thereof without
departing
from the scope of the invention. In addition, many modifications may be made
to
adapt a particular situation or material to the teachings of the invention
without
departing from the essential scope thereof. Therefore, it is intended that the
invention
not be limited to the particular embodiment disclosed as the best mode
contemplated
for carrying out this invention, but that the invention will include all
embodiments
falling within the scope of the appended claims.
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